Truckless System

Replacing fixed crushers and off highway trucks (OHT), the system uses movable crushers and conveyor belts. Instead of the 100 off-highway trucks that would be required for this task, a structure comprised of shovels and movable crushers will extract the iron ore and feed about 30 kilometers of conveyor belts, which will lead the product to the processing plant. This replacement, in addition to reducing the amount of waste, such as tires, filters and lubricants, will enable a 77% reduction in fuel consumption.

Natural humidity processing

The processing with natural humidity waivers any additional use of water and uses the humidity in the ore itself to remove impurities. This system will reduce water consumption in 93%, which corresponds to the water supply for a city with 400k inhabitants. By adopting this technology, we will also reduce the consumption of electric energy. Another advantage is the elimination of tailings dams, since the ultrafine fraction of high grade iron ore, which would end up in the dam, will not be disposed of - this means that, over the 30 years of the mine’s expected service life, 300 million tons will be incorporated back into production.

Modularization

The plant structures have been assembled, welded and bolted as if they were large Lego pieces. This technology allowed the modules - 109 in total, weighing from 80 to 1.3 thousand tons - to be assembled in a Vale area a little over 40Km away from where the plant is being built. A road was specially prepared and paved to support the weight and dimensions of the modules and then will be donated to the government of the State of Pará, bringing benefits to the local community.

Advanced automation and control system

Among the modern automation and control practices adopted in the S11D, we can highlight the more efficient management of energy resources, using smart devices that adequate the supply of raw materials according to process demands. The automation network controls all variables involved, deactivating unnecessary equipment and consumption points in case of low demand or load. Additionally, it uses frequency inverters to replace conventional couplings, which increases energy yield even more.

Drone

The S11D will use the latest generation drone to carry out aerophotogrammetric survey work of the mine areas, plant and ore pile. These images will support short-term mine planning, adding security, agility and accuracy to topography activities.

Simulators

Training for wagon loads operators with the iron ore is being done with the help of a simulator. The equipment installed in the S11D Training Center is an important tool for the development of the professionals, who start the activities in a better prepared area.